Machine for and a method of manufacturing a laminate particularly adapted for bedding, padding, upholstering and like applications

ABSTRACT

A method of manufacturing a laminate particularly adapted for bedding, padding upholstering and like applications by feeding an indeterminate length of a first material along a predetermined first path of travel from a source of the first material to a downstream assembly area. Feeding an indeterminate length of second material along a predetermined second path of travel from a source of the second material to the downstream assembly area. Depositing a multiplicity of substantially yieldable cushioning materials upon an upper surface of one of the first and second indeterminate lengths of material during the feeding thereof between the respective sources and the assembly area. Thereafter, sandwiching the cushioning materials between the indeterminate lengths of first and second materials to form a laminate therefrom, and rolling the laminate into a roll. The cushioning materials are foam latex and/or down and the first and second lengths of material are polyester fiber material and/or convoluted foam.

BACKGROUND OF THE INVENTION

[0001] A mattress normally includes a coil spring unit defined by aplurality of interconnected coil springs which are united to each otherand to upper and lower polygonal frame wires which impart a generallyrectangular configuration to the coil spring unit. An upper or topmattress pad and a lower or bottom mattress pad, each formed of multiplelayers or plies of materials stitched together, and a like narrowperipheral mattress pad, also formed of multiple plies or layers, areassembled to entirely encapsulate the coil spring unit and form themattress.

[0002] The top, bottom and peripheral mattress pads are each formed as alaminate which might, for example, include a backing material layer, afoam material layer, a fiber material layer and a ticking layer, allstitched together by stitching of a conventional “quilt” pattern ordesign. The materials of the latter layers, the thicknesses thereof,etc. all contribute to such characteristics as softness, breathability,wear, etc. However, irrespective of the particular layers, it isimportant that the upper mattress pad and the lower mattress pad aremanufactured as inexpensively as possible, yet provide the best mattresscharacteristics possible at the lowest equitable cost over the longestmattress life possible.

[0003] A typical conventional mattress corresponding to the mattressjust described is disclosed in U.S. Pat. No. 5,317,768 granted on Jun.7, 1994. The patent discloses a spring component and at least a topsurface component formed as a laminate with the outer layer being theticking or cover fabric, the next inboard layer being a fiber layer, thethird layer being a convoluted foam layer, and the innermost fourthlayer being a cotton layer with associated stitching holding all four ofthese layers together to form a quilted multi-ply mattress pad. Thethickness of the fiber layer and the thickness of the convoluted foamlayer are said to be matters of design choice, though specific examplesof weight per square foot of the polyester fiber and the height of theconvoluted foam layer are specified as being illustrative. However, itis generally conceded that the best mattresses providing the mostcomfort are those which include an appreciably thick layer of convolutedfoam. However, foam material, particularly latex (natural rubber) foamis extremely expensive and, therefore, appreciably thick convolutedlatex foam layers are found most exclusively in higher end, moreexpensive mattresses. It would be highly desirable to increase the latexfoam content in lower end mattresses (less expensive) if costs could bemaintained relatively low during the manufacture thereof such that as anend result virtually all qualities of the mattress are appreciablyincreased at a moderate or low increase in cost at both the wholesaleand retail levels.

SUMMARY OF THE INVENTION

[0004] In keeping with the foregoing, it is a primary object of thepresent invention to provide as an end product a novel mattress whichincludes a conventional coil spring unit and at least a top or uppermattress pad formed of multiple plies or layers including at least onefiber layer and one convoluted foam latex layer having conventionalpeaks and valleys with the valleys being each substantially filled witha multiplicity of relatively inexpensive, small, random sized, foamlatex pieces/materials which might otherwise be discarded as scrap, yetpossess all of the highly desirable characteristics of a solid latexfoam layer. Since the relatively small pieces of foam latex areentrapped in the valleys during lamination, as will be described morespecifically herein, the manufacture of such an upper and/or lowermulti-ply mattress pad is relatively inexpensive and, thus, can beutilized to enhance all grades of conventional mattresses now beingproduced, sold and used throughout the world.

[0005] In further accordance with the present invention, such relativelysmall random sized pieces of latex foam material are also preferablysandwiched between two layers of fiber material, such as conventionalpolyester fiber, to form an upper mattress pad, a lower mattress padand/or a peripheral mattress pad formed of three plies, namely, apolyester fiber ply or layer, a layer of latex foam pieces and anotherpolyester fiber ply or layer. As thus far described and as opposed tothe first laminated mattress pad herein described, the small individualpieces of latex foam (hereinafter termed “latex”) would tend to shift ormove when in use as part of a mattress, unless otherwise provided for,as is the case of the present invention in which the two polyesterlayers are stitched together by a conventional quilting machine whichnot only secures the layers together as a unit, but the stitchingconfines or limits the movement or “migration” of the latex when used,for example, as the upper and/or lower mattress pads of a mattress.Thus, conventional stitching of the quilting process not only functionsto maintain the two polyester fiber layers (or any other additionallayers) united, but the stitching additionally precludes undesired latexmigration/shifting which essentially maintains uniform latex thicknessand results in a very comfortable yet inexpensive mattress available atlow and moderate prices while providing moderate to high quality comfortand softness absent localized “hard” spots, as might otherwise occurwith undesired latex migration.

[0006] In keeping with the foregoing, the last described mattress pad isformed by a novel laminating machine of the present invention whichprovides respective first and second means for rotatably supportingfirst and second rolls of polyester fiber material with an upper surfaceof a layer or web of the first roll being fed beneath a trough fromwhich latex/latex pieces are fed. Downstream of the trough a secondlayer or web of the second roll of polyester fiber material is overlayedupon the pieces of latex at an assembly area during the continuoustravel of the polyester fiber layers toward a roll forming or windingstation. The thus formed laminate (polyester fiber layer/latexpieces/polyester fiber layer) are then preferably wound into a roll oflaminate/laminate roll, the laminate is cut upstream of the roll, andthe laminate roll is packaged and shipped to a mattress manufacturer forutilization in the manufacture of a mattress as described earlierherein. An area is provided for storing packaging material, such as aroll of transparent polymeric/copolymeric packaging material, adjacentthe roll forming station to use as the packaging material for thelaminate roll. Obviously, the diameter of the laminate roll and itslength will vary dependent upon the thicknesses of the polyester fiberlayers and the amount of latex sandwiched therebetween. No matter thelength, width or diameter of the laminate roll, preferably a flyingshear or flying cutter severs the laminate normal to the direction oftravel in response to automated or manual controls immediately uponcompletion of the roll packaging operation.

[0007] Immediately upon effecting lamination at the lamination orassembly area, the longitudinal edges of the polyester fiber layers aresubject to an edge-binding operation which is preferably achievedthrough spraying a fast drying adhesive therealong which virtually driesinstantaneously under normal temperature ranges found in factories, butheaters may be used, as necessary. The adhesive thus sprayed along thelongitudinal edges binds all edge-exposed latex pieces to each other andto the polyester fiber layers. Alternatively or additionally,compression edge rollers can be utilized downstream of the adhesivespray applicators, preferably spray guns, to bring the polyester layersinto intimate adhesive bonding contact, thereby further assuring thatthe latex/latex pieces cannot escape the laminate.

[0008] In lieu of immediately forming the laminate into a roll, cuttingthe laminate, packaging the laminate roll and shipping the same to anend user, the laminate may be fed directly into a quilting machine andconventionally quilted or stitched to not only provide unification ofthe layers and the attendant conventional “quilted” appearance ofmattresses, but to also prevent latex “migration.” Conventional quiltingmachines have multiple programmable stitching heads and in accordancewith the present invention, such stitching heads are programmed not onlyto provide an aesthetic quilt appearance, but to also create essentiallya multiplicity of relatively small “closed” pockets between thepolyester fiber layers defined by the threads of the stitching with thethreads or stitching of each “pocket” confining the latex therein andsubstantially preventing latex migration outwardly of each stitchedpocket. The simplest example of the latter is stitching the laminateprior to rolling or immediately upon being unrolled at a mattressfabricator by closely spaced rows of stitching normal and parallel tothe direction of travel of the laminate (rolling direction of thelaminate roll) to form substantially square or polygonal “closed”pockets, each being relatively “closed” by the stitching associatedtherewith. Though such “closed” pockets of stitching are desirable, thestitching need not define completely “closed” pockets, but the stitchinginstead might be configured such as to prevent excessive migration as,for example, closely adjacent parallel sinusoidal stitching eitherlengthwise or widthwise of the laminate which forms narrow sinusoidalchannels which essentially prevent latex migration by the very curvednature thereof and the relatively narrow width of each channel.

[0009] The trough which houses the latex preferably includes a tubularpolygonal rubber chute carrying at a lower end a latex proportioninggate having a plurality of proportioning openings therein through whichpass the latex for deposit upon the upper surface of the polyester fiberlayer being conveyed therebeneath. The openings in the gate or platevary in number, size, shape and orientation depending upon the range ofsizes of the particles of the latex being fed therethrough, the amountof latex which is to be deposited per square foot/yard (and thus theeventual height thereof) upon the upper surface of the underlyingpolyester fiber layer, the speed of production, etc. Gates varying inopening numbers, sizes, shapes and configurations are provided inaccordance with the invention for selective utilization to manufacturevirtually any and all end product characteristics, such as latex height,density, etc.

[0010] The rubber chute or the gate also carries spacers which engagethe upper surface of the polyester fiber layer passing therebeneath andassures that this upper surface is spaced at all times a minimumdistance from the gate/plate openings. The minimum distance correspondsto the maximum height of the layer of latex which is to be applied tothe underlying polyester fiber layer. Since the underlying polyesterfiber layer is in continuous motion as it is conveyed toward theassembly/laminating area, its inherent resilience evokes up-and-downmovement during the conveyance thereof which, if excessive in an upwarddirection, will cause the upper surface of the polyester fiber layer tomove undesirably closer to the gate openings resulting in the height ofthe latex being lessened and lessened appreciably beyond that desired.Thus, by maintaining the gate openings at a predetermined minimumdistance from the upper surface of the underlying polyester fiber layerduring its movement, the thickness/height of the latex is at all timesmaintained at a uniform desired maximum height which in turn results ina laminate of uniform cross-sectional thickness throughout.

[0011] The trough also includes a pair of trough plates, one fixed andanother which is adjustable, and between the two trough plates is a vanefeed roll or roller which can be rotated at different speeds dependentupon the desired rate of feed of the latex. Lower edges of the troughplates define a transverse slot which can be increased in size by movingthe edge of the movable trough plate away from the fixed trough plateand decreased in size by opposite motion for varying the rate of feed ofthe latex in conjunction with the speed of rotation of the vane feedroll or vane feeder.

[0012] The laminating machine also includes a drive mechanism for thetake-up roll or roll forming mechanism which is variably adjustable inrotational speed while shafts supporting the rolls of polyester fiberlayers or webs are under constant tension of a conventional adjustablebrake mechanism. The tension is relatively slight but sufficient tomaintain the upper surface of the polyester fiber layer passing beneaththe trough relatively horizontally disposed to prevent vertical motionand/or bowing during travel, and thereby assures maximum uniformity ofthe height of the latex deposited thereupon. Thus, by manually orautomatically adjusting the speed of rotation of the shaft upon whichthe laminate is being wound to form the laminate roll, the amount oflatex being deposited upon the upper surface of the underlying polyesterfiber layer can be further regulated in conjunction with the earliermentioned adjustable trough plate, adjustable vane feeder, and differentproportioning gates.

[0013] The laminating machine can also be utilized to form a multi-plyor laminated mattress pad defined by a convoluted latex foam layerhaving a relatively flat surface and an opposite surface defining peaksand valleys, latex particles housed within the valleys, and a polyesterfiber layer. The latter-described mattress pad is manufactured by thelaminating machine in the manner just described with the exception thatthe downstream roll of polyester fiber material is not utilized, and inlieu thereof a roll of convoluted latex foam is supported upon anassociated shaft and is drawn therefrom with its peaks and valleysrespectively pointing toward and opening toward the upper surface of theunderlying polyester fiber layer. In this fashion as the latex particlesdeposited upon the upper surface of the lower polyester fiber layer passbeneath and are united with the convoluted latex foam layer, the latexparticles are entrapped/encapsulated within the valleys or “pockets” ofthe convoluted latex foam layer. The laminate thus formed is rolled intoa laminate roll and/or stitched by a conventional quilting machine,though the quilt pattern need not provide stitching “pockets,” as in thecase of the polyester fiber layer/foam latex particles/polyester fiberlayer laminate, because the valleys are the “pockets” and prevent latexmigration.

[0014] With the above and other objects in view that will hereinafterappear, the nature of the invention will be more clearly understood byreference to the following detailed description, the appended claims andthe several views illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of a novel laminating machineconstructed in accordance with this invention, and illustrates foamlatex particles being deposited upon an upper surface of a polyesterfiber layer or web being drawn from a roll, and another polyester fiberlayer being applied thereto forming a laminate which is formed into alaminate roll and is packaged for delivery to a mattress manufacturer.

[0016]FIG. 2 is an enlarged cross-sectional view taken generally alongline 2-2 of FIG. 5 through a trough which houses the foam latexparticles, and illustrates a fixed and a movable trough plate, a vanefeeder, and a rubber chute through which the foam latex pieces movesincident to being deposited upon an upper surface of the polyester fiberlayer passing beneath the trough.

[0017]FIG. 3 is an enlarged fragmentary cross-sectional view of themovable and fixed trough plates and the vane feeder therebetween, andillustrates one of many different relative positions to achieve desiredlatex feed therethrough.

[0018]FIG. 4 is a fragmentary enlarged perspective view similar to FIG.3, and illustrates another relative position of the fixed and movabletrough plates and the vane feeder which alters the relative size of thetransverse slot, as compared to FIG. 3, and thereby varies the rate oflatex feed.

[0019]FIG. 5 is an enlarged fragmentary cross-sectional view takengenerally along line 5-5 of FIG. 1, and illustrates a drive for the vanefeeder and a portion of a linkage for varying the adjusted position ofthe movable trough plate.

[0020]FIG. 6 is a fragmentary top perspective view looking downwardlyinto the trough, and illustrates a removable trough end plate partiallyremoved to provide access to journals and bearings associated with themovable trough plate and the vane feeder.

[0021]FIG. 7 is a fragmentary top perspective view of the left side ofthe trough, as viewed in FIG. 1, and illustrates a handle and a screwthread received in an internally threaded sleeve of the linkage foradjusting the position of the movable trough plate.

[0022]FIG. 8 is a bottom perspective view of a spacer assembly, andillustrates a spacer frame carrying three convex spacer rods.

[0023]FIG. 9 is a bottom perspective view of a proportional feed gate orfeed plate, and illustrates a plurality of substantially identicallyshaped rectangular openings thereof.

[0024]FIG. 10 is a fragmentary bottom perspective view of anotherproportional feed gate or feed plate, and illustrates openings of twodifferent sizes formed therein.

[0025]FIG. 11 is a bottom perspective view of another proportional feedgate or feed plate, and illustrates a further group of feed openingsformed therein.

[0026]FIG. 12 is a fragmentary longitudinal cross-sectional view takengenerally along line 12-12 of FIG. 1, and illustrates the proportionalfeed gate of FIG. 9 and the spacer assembly of FIG. 8 removably securedto a lower terminal edge of the rubber chute with the convex spacer rodstouching an upper surface of the underlying polyester fiber layer.

[0027]FIG. 13 is a fragmentary longitudinal cross-sectional view similarto FIG. 12, and illustrates a roll of convoluted foam latex in lieu ofthe downstream roll of polyester material of FIG. 12.

[0028]FIG. 14 is an enlarged fragmentary longitudinal cross-sectionalview of the lamination of FIG. 13, and illustrates a multiplicity ofrandomly sized latex particles/pieces substantially filling downwardlyopening valleys or pockets of the convoluted latex foam layer.

[0029]FIG. 15, which appears on the sheet of drawing containing FIG. 7,is a fragmentary top perspective view of a modification of thelamination machine of FIG. 1, and illustrates the polyester fiberlayer/latex foam pieces/polyester fiber layer laminate being fed into aconventional quilting machine and both transverse and longitudinalsinusoidal stitching forming substantially closed pockets to preventlatex migration.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] A novel machine for manufacturing a laminate particularly adaptedfor use in bedding (mattresses), padding, upholstering and likeapplications is fully illustrated in FIG. 1 of the drawings and isgenerally designated by the reference numeral 10.

[0031] The laminate manufacturing machine or laminating machine 10includes first means 11 for feeding an indeterminate length or layer L1of first material M1, such as polyester fiber, from a roll R1 thereofalong a first predetermined path of travel P1 (FIGS. 1 and 12) which isfrom left-to-right in each of the two latter figures toward a downstreamassembly or laminating area A (FIG. 1).

[0032] Second means 12 are provided for feeding another indeterminatelength or layer L2 of second material M2 of polyester fiber from a rollR2 along a predetermined second path of travel P2 (FIG. 1). The paths oftravel P1, P2 are for the most part substantially in the same directionand are substantially horizontally disposed.

[0033] Means 13 are provided for depositing a multiplicity ofsubstantially yieldable cushioning materials L, such as pieces of foamlatex of random sizes, upon an upper surface Us of the polyester fiberlayer L1 of a predetermined height H (FIG. 12) in a manner to bedescribed more fully hereinafter. The pieces of foam latex L aredeposited upon the upper surface Us of the polyester fiber layer L1upstream of the roll R2 of the polyester fiber layer L2, as is evidentfrom FIGS. 1 and 12 of the drawings. The latex L is deposited upon theupper surface Us of the polyester fiber layer L1 in varying amountsdepending upon such factors as the quality of the latex L, whether themattress to be formed therefrom will be low, moderate or high priced,etc., but for the most part the latex L deposited upon the layer L1 willrange between 0.15-0.30 pound per square yard of the layer L1. The rangecan, of course, be lessened for less expensive end product productionand increased for higher priced end products, as, for example, thedeposited latex L might be between 0.10-0.50 pounds per square yard.Latex and down, admixed 50%/50% can also be used as the layer L in thepreferable range of 0.15-0.30 pound per square yard and up to thebroader 0.10-0.50 pound per square yard range.

[0034] Means 15 in the form of identical adhesive spraying mechanismsare located along opposite longitudinal edges (unnumbered) of the layersL1, L2 and the eventually formed laminate Lm which direct an adhesivespray S therealong to edge-bind/edge-bond the longitudinal edges of thelayers L1, L2 to each other.

[0035] Means 16 in the form of an upper roller 17 and a lower roller 18temporarily compress the laminate Lm during the passage therebetween toeffectively close the longitudinal edges of the layers L1, L2 andpreclude the latex L from being dislodged outwardly of the layers L1,L2.

[0036] Means 20 are provided for rolling the laminate Lm into a laminateroll Lr.

[0037] When the laminate roll Lr is of a desired size, an operator or anappropriate conventional microcontroller Mc, such as Motorollamicrocontroller C68HCO5J2P, which contains a variety of input/outputpins that are programmable to effect a multiplicity of functionsincluding that of appropriately controlling cutting means 22, such as aconventional flying shear or flying cutter, which cuts the laminate Lmnormal to the direction P1, P2 thereby freeing the laminate roll Lr forsubsequent packaging and shipment.

[0038] Means 24 support a roll R3 of packaging material, such as a rollof polyethylene P, above the roll of laminate Lr. The polyethylenematerial P is simply drawn from the roll R3, wound about the roll oflaminate Lr, severed from the roll R3, and appropriate edge-to-edgesealed to encase, protect, and package the laminate roll Lr therein forsubsequent shipping to a mattress manufacturer or the like.

[0039] The first feeding means or first feeding mechanism 11 includesopposite uprights 30 of which only one is illustrated in FIG. 1 andbetween which is rotatably supported a shaft 31 which is in intimatefrictional engagement with the innermost convolution of the roll R1. Aconventional adjustable brake 32 can be adjusted by a worker or by themicrocontroller Mc to maintain desired drag on the layer L1 as it isdrawn from the roll R1 by the roll forming mechanism 20 in a manner tobe described more fully hereinafter. The brake or brake means 32, nomatter the specifics of the construction thereof, is relativelyconventional and is designed simply to assure that sufficient pull ortension is applied to the layer L1 to maintain the same substantiallyhorizontal with little bow therein during movement along the path P1.The tension is augmented by a top roller 33 spring biased downwardlywhich spans the width of the layer L1, the purpose of which is totake-up any minute “slack” which might otherwise occur in the layer L1during its movement along the path of travel P1.

[0040] The lower layer L1 is preferably freely fed absent lower supportfrom the point of take-off from the roll R1 until it enters between therollers 17, 18. However, a lower surface Ls (FIG. 12) of the layer L1may be supported upon an upper surface (unnumbered) of a relativelysmooth glide plate Gp formed of material having an extremely lowco-efficient of friction or coated with such material, such as syntheticfluorine-containing resins (Teflon®). In lieu of the guide plate Gp, aplurality of transverse conveyor rollers (not shown) may be utilized toassure that the upper surface Us of the layer L1 is at a fixed heightduring the passage thereof through the foam latex depositing means 13.

[0041] The latex depositing means 13 includes a trough 40 conventionallysupported by a frame F in transversely spanning relationship to thelayer L1. The trough 40 is defined by an upstream wall 41 and adownstream wall 42 which converge relative to each other in a downwarddirection. The walls 41 and 42 are welded to a side wall 43 and oppositethereto the walls 41, 42 are similarly welded to an outboard oppositeside wall 44 (FIGS. 5 and 6). A removable inboard side wall 45 (FIGS. 5and 6), when m seated in its operative position (FIG. 5), covers andprotects housings and bearings of linkages and shafts to be describedmore fully hereinafter. This protects the housings, bearings and shafts,yet provides ready access thereto for repair or replacement by simplygripping and pulling the removable inboard side wall 45 upwardly fromthe position shown in FIG. 5 to that shown in FIG. 6.

[0042] Lowermost terminal edge portions 51, 52 (FIG. 2) of theconverging walls 41, 42, respectively, are generally in parallelrelationship to each other, and these collectively define with loweredge portions (unnumbered) of the end walls 43, 45 a transverse opening60 above and extending entirely across the layer L1 as it passestherebeneath.

[0043] Housed within the trough 40 and extending substantially theentire length of the transverse opening 60 are means 70 forcooperatively adjustably varying the size of the transverse opening 60and between which is located rotatable feed means 80 for regulating thepassage of the latex L through the transverse opening 60.

[0044] The opening size adjusting means 70 include a fixed trough plate71 and a movable trough plate 72 (FIGS. 2, 5 and 6). The fixed troughplate 71 is welded along its entire length to the downstream wall 42 andto the side wall 43, but not to the removable inboard side wall 45. Themovable trough plate 72 is welded along its entire length to a shaft 73which at the end adjacent the removable inboard side wall 45 passesthrough a slot 47 thereof (FIG. 6). The shaft 43 passes through abearing (not shown) of a bearing housing 74 (FIG. 6) and passes throughan opening (not shown) in the outboard wall 44 (FIG. 7) beyond which itis connected to a linkage 75 (FIG. 7). The opposite end of the shaft 73is received in a bearing and a housing corresponding to the housing 74mounted adjacent the side wall 43 (not shown). The trough plate 72 canthereby pivot selectively and adjustably relative to the fixed troughplate 71 and the rotatable feed means 80 in the manner diagrammaticallydepicted in FIGS. 3 and 4 of the drawings to thereby vary the size ofthe transverse opening 60 to selectively vary the rate of feed of thelatex L therethrough under any one particular speed of rotation of therotatable feed means 80. In other words, though the rotatable feed means80 can be varied in its rotational speed, changes in the amount of latexL discharged through the transverse opening 60 can be altered by merelypivoting and changing the position of the pivotable trough plate 72relative to the rotating feed means 80 and the fixed trough plate 71.

[0045] The means or mechanism for varying the position of the troughplate 72 includes trough plate adjusting means 90 (FIG. 7) in the formof a threaded screw 91 having an unthreaded end 92 jounalled forrotation in a bearing (not shown) fixed to a housing wall 93 andcarrying a handle 94. An internally threaded sleeve 95 forms part of thelinkage mechanism 75 (FIGS. 5 and 7) and threadably receives therein thethreaded shaft 91. Links 96, 97 (FIG. 7) are pivotally connected to thesleeve 95 by a pivot pin 98 while opposite ends of the links 96, 97 havefixed thereto the shaft 73, as by welding, of the trough plate 72. As isreadily apparent from FIG. 7 of the drawings, as the handle 94 of thetrough plate adjusting means 90 is rotated in either of two directions,the threaded shaft 91 will thread into or out of the sleeve 95 to pivotthe links 96, 97 which in turn rotate the shaft 73 which in turn pivotsthe movable or pivotable trough plate 72 to achieve the selectedvariation in size of the transverse opening 60 (FIGS. 2 through 4).

[0046] The rotatable feed means 80, which also regulates the passage ofthe pieces of latex L through the transverse opening 60 through selectedspeeds of rotation, is defined by a rotatable vane feeder 81 having acentral cylindrical portion 82 and five equally arcuately spacedradially outwardly directed vanes 83 projecting therefrom. Thecylindrical central portion 82 is reduced in size at opposite endportions, and one such end portion 84 is illustrated in FIGS. 5 and 6 ofthe drawings projecting through a downwardly opening slot 48 of theremovable inboard side wall 45 and being journalled for rotation in abearing of a bearing housing 85 (FIG. 5) bolted to the outboard sidewall 44. A bearing housing (not shown) corresponding to the bearinghousing 85 secures the opposite reduced end (not shown) of thecylindrical portion 82 of the rotatable vane feeder 81 to the side wall43. The end portion 84 projects through an opening (unnumbered) in theoutboard side wall 44 (FIG. 5) and is driven by a conventionalright-angle drive 86 of an electric motor 87 which is controlled indirection of rotation and speed of rotation by the microcontroller Mc orone of several conventional manually operated adjustable electricswitches, such as a switch 89 (FIG. 1) fixed to the wall 93 of thetrough 40. As the speed of rotation of the rotatable vane feeder 80 isincreased, more latex L is fed through the transverse opening 60,irrespective of the size thereof, while a decrease in rotational speedof the rotatable vane feeder 80 effects the opposite result.

[0047] As the latex L descends vertically downwardly under the influenceof gravity through the transverse opening 60, it passes through and isguided by guide means 100 in the form of a rubber guide chute or sleevehaving a generally rectangular cross-sectional configuration, as viewedfrom above and below, and terminates in a lower polygonal terminal edgeportion 101 spaced the height H (FIG. 12) above the upper surface Us ofthe polyester fiber layer 1. The height H represents the maximum heightof the latex L that will under any circumstances be deposited atop theupper surface Us of the layer L1.

[0048] Spacer means 110 (FIG. 8) and latex feed proportioning means 120(FIG. 9) are each carried by the lower terminal edge portion 101 of theguide chute or sleeve 100.

[0049] The latex feed proportioning means 120 is a feed gate or feedplate of a generally rectangular configuration having an upper flange121 of a polygonal configuration whose internal size matches theexterior size of the terminal end portion 101 of the guide chute 100.Thus, the terminal end portion 101 of the guide chute 100 can be slippedinto the upper flange 121 of the proportional feed gate 120 and securedthereto by fasteners, such as screws or clips 122 (FIGS. 12 and 13)passed through openings 119 of the upper flange 121. A plurality of likesized generally rectangular identically spaced proportioning openings123 are formed in the proportioning plate 120 and it is through theproportioning openings 123 that the latex L passes before beingdeposited upon the upper surface Us of the layer L1. Since the openings123 are substantially equally spaced and identically sized, they assurethat no matter the existence of any inconsistencies in content or volumeof the latex L falling through or accumulating in the chute 100,substantially equal amounts of latex L will fall through each opening123 to create a substantially uniform and consistent height H. Differentopenings 123′ (FIG. 10) and 123″ (FIG. 11) of respective proportionalfeed plates 120′, 120″ afford effective dispensing of latex L dependentupon differences in relative sizes of the pieces of latex L, the heightH which must be achieved, the speed of production, etc. In other words,if the pieces of latex L are of one size or a specific size range, theproportional feed gate 120 might be utilized to obtain a desired heightH, whereas should the pieces of latex L be of a different size, range ofsizes or consistency, the proportioning plate 120′ or the proportioningplate 120″ might be instead utilized. However, no matter the particularproportioning plate 120, 120′ or 120″ which is secured to the terminaledge portion 101 of the guide chute or sleeve 100, the selection thereofwill assure the exact height H and consistency of the latex pieces Ldeposited upon the polyester fiber layer L1 under all manufacturingprotocols, such as the speed of rotation of the laminate roll Lr, thespeed of rotation of the vane feeder 81, the size of the transverseopening 60, etc.

[0050] The spacing means 110 is a spacer assembly defined by a polygonalframe 111 having a plurality of openings 112 therein matching thelocation of the openings 119, 119′, 119″ of the proportional feed plates120, 120′, 120″. The internal size of the frame 111 of the spacerassembly 110 substantially matches the external size and configurationof the flanges 121, 121′, 121 ″ of the respective proportional feedplates 120, 120′ and 120″. The frame 111 can be telescoped upon andsecured to the flanges 121, 121′, 121″ and/or the terminal edge portion101 of the chute 100 by utilizing conventional fasteners, such as thefasteners 122 (FIGS. 12 and 13). Projecting downwardly from the frame111 in a convex fashion are three relatively narrow spacer rods 125which are parallel to the direction of travel P1 and which contact theupper surface Us of the layer L1 (FIG. 12) maintaining it at all timesspaced the distance H, thus assuring no matter the vertical deflectionor flexing of the layer L1 during its movement, the height H of thelatex L deposited upon the upper surface Us will never be less than theheight H. Though not illustrated, spacer assemblies corresponding to thespacer assembly 110 can be provided as substitutes therefor with thecurvature or the spacer bars 125 being lesser or greater than that shownto respectively decrease and increase the height H to achieve lesser orgreater height H than that illustrated in FIG. 12. In lieu of additionalspacing means, the spacing means 110 may be modified in the mannerillustrated in phantom outline (dashed lines) in FIG. 8 whichillustrates an increase in the overall height of the frame 111 withadditional openings 112 being also shown in phantom outline in verticalspaced relationship to each other. There are three such vertical spacedopenings shown in the frame 111, and depending upon which of these areutilized to fasten the frame 111 to the lower edge portion 101 of thechute 100, the distance of the spacer bars 125 from the upper surface Usof the polyester fiber layer L1 can be variably adjusted to occupy anyone of three positions thus assuring three different distances for theheight H of the latex L deposited upon the upper surface Us of thepolyester fiber layer L1.

[0051] The means or mechanisms 15 (FIG. 1) for edge-binding/edge-bondingthe layers L1, L2 to each other, along with the foam latex pieces Lsandwiched therebetween, are a pair of conventional spray nozzles 130connected by a flexible tube or conduit 131 and a conventionaladjustable valve 132 to an adhesive-containing reservoir 133. Theadhesive (not shown) within the reservoir 133 is nontoxic, extremelyquick drying, and is preferably controlled in its application throughsuitably adjustably controlling the valve 132 through themicrocontroller Mc in a conventional manner. The spray S emitted fromthe spray nozzles 130 are applied to the opposite longitudinal edges(unnumbered) of the layers L1, L2 and any of the latex particles Lexposed therebetween, as is evident from FIG. 1 of the drawings. Theadhesive will bind all of the exposed latex particles L to each otherand to the longitudinal edges of the layers L1, L2, through preferablyprior to the adhesive drying, the layers L1, L2 and L pass through therollers 17, 18 of the roller compression mechanism or means 16 which arepreferably spring-biased toward each other in a conventional manner orthrough pneumatic fluid cylinders (not shown) to apply desired pressureto the longitudinal edges substantially closing the same incident to theadhesive drying such that the latex L is essentially unexposed afterpassing beyond the rollers 17, 18.

[0052] The microcontroller Mc controls the flying cutter or flying shear22 to transversely cut the completed laminate Lm after the laminate rollLr has been formed to a desired length (diameter) followed by wrappingthe same in the packaging material P for shipment to a subsequent user,such as a mattress manufacturer.

[0053] The laminate roll Lr is preferably driven by a right-angled drive140 selectively driven by an electric motor 141 controlled manually byan adjustable rheostat 142 or through the microcontroller Mc. Likeconventional control means 143 (FIG. 1) can be manually adjusted to varythe braking of the roll R1 through the conventional brake 32 or in lieuthereof, the brake 32 can also be controlled by the microcontroller ormicroprocessor Mc.

[0054] In lieu of the edge-binding/edge-bonding means 15, theutilization of conventional stitching heads (not shown) may be providedto sew the longitudinal edges of layers L1, L2 to each other during theperformance of the lamination process/method.

[0055] A walkway W (FIG. 1) preferably traverses the paths of travel P1,P2 between the latex depositing mechanism 13 and the support means 12for the roll R2 of polyester fiber material M2 or the equivalent. Thewalkway W serves as a substantially central area or location at which anoperator can view the entire laminating machine 10 and the variouscomponents thereof to operate any of the switches or adjusting means 89,142, 143 or the microcontroller Mc, as well as the hand wheel 94 which,though manually rotated, can as well be power driven in a conventionalmanner under the control of the microprocessor or microcontroller Mc.However, whether under a program control from a personal computer (PC)associated with the microcontroller Mc (FIG. 1) or manually, the amountof the latex L deposited upon the layer L1 of polyester fiber materialcan be varied to in turn vary the height H and/or the consistencythrough a variety of adjustments, as, for example:

[0056] (1) The driving means 20 can be increased or decreased torespectively speed up or reduce the speed of the layer L2 which, withall other factors remaining the same, will respectively decrease andincrease the height H of the latex L.

[0057] (2) Obviously, by increasing or decreasing the speed of the motor87 (FIG. 5) the rotation of the vane feeder 81 (FIG. 2) can be varied toagain regulate the height H (FIG. 12) of the latex material L.

[0058] (3) Manipulating the pivotable trough plate 72 (FIG. 2) to varythe size of the slot 60 will also selectively vary the height H of thelatex L1 deposited upon the layer L1 (FIG. 12).

[0059] (4) Alternating the particular proportioning plate 120, 120′ and120″ and/or the spacer assembly 110 or its vertical height relative tothe chute 100 via the vertically offset openings 112 can also beutilized to selectively vary the height H of the latex L deposited uponthe layer L1.

[0060] Virtually any combination of adjustments (1) through (4) abovecan be utilized to vary the final end product of the laminate Lm.

[0061] A modification of the laminating machine 10 of FIG. 1 is shown inFIG. 15 to which attention is now directed, and in this case themodified laminating machine is designated by the reference character 10′and includes all of the components of the laminating machine 10 exceptfor the flying shear or flying cutter 22, and in lieu thereof issubstituted a conventional quilting machine Qm having a multiplicity ofconventional quilting heads (Qh) which stitch the laminate Lmimmediately upon passing beyond the rollers 17, 18 of the compressingmeans 16 and prior to being formed into a roll L′r. The laminate rollL′r is generally fed simultaneously through the quilting machine Qm upona web of underlying cloth material Cm drawn from an associated clothmaterial roll Cmr. The individual stitching or quilting heads Qh of thequilting machine Qm can be variably adjusted in a conventional mannerfor quilting any one of numerous different stitching patterns orquilting patterns upon the laminate L′m. However, in keeping with thepresent invention, the laminate or laminate material L′m is shown beingstitched therethrough with substantially parallel sinusoidallongitudinal stitching Ls and substantially sinusoidal paralleltransverse stitching Ts with the stitching Ls and Ts forming individualnarrow sinusoidal longitudinal channels Lc and Tc, respectively,therebetween. At the crossings of the stitching Ls and Ts are formedindividual substantially closed pockets Cp with each substantiallyclosed pocket Cp being bounded by portions of two of the longitudinallines of stitching Ls and portions of two of the transverse lines ofstitching Ts. The latter described stitch crossings not only define thesubstantially closed pockets Cp, but the stitching and closed pockets Cpprevent excessive movement or “migration” of the latex L from each ofthe pockets Cp which is highly desirable when the laminate material L′mis made into a mattress, for example. When, for example, a portion ofthe laminate L′m is formed as an upper layer of a mattress and a personlies and moves thereupon for days, months or years at a time, the latexL will not migrate but instead will remain in each of the substantiallyclosed pockets Cp and the uniformity and consistency of the mattressthus manufactured will be maintained substantially for its entirelifetime.

[0062] While the closed pockets Cp are a preferable form of thestitching, migration of the latex L of the laminate L′m is substantiallylessened even absent such “closed” pockets. For example, if thetransverse stitching Ts were eliminated, the very nature of thenarrowness and the sinusoidal curvature of the longitudinal channels Lcwould materially preclude migration in the longitudinal direction andwould, of course, totally preclude migration in the transversedirection. Obviously, the opposite is true, namely, if the longitudinalstitching Ls were eliminated, the sinusoidal curvature and thenarrowness of the transverse channels Tc would substantially lessenmigration of the latex L in the transverse direction and, of course, thetransverse stitching Tc would totally preclude migration of the latex Lin the longitudinal direction. Therefore, the stitching of the laminateL′m need only be such as to define an overall pattern which wouldsubstantially lessen or preclude migration of the latex L between thelayers L1, L2, irrespective of the “closed” or “open” nature thereof,through substantially “closed” pockets Cp and equivalents thereof arepreferred.

[0063] In further accordance with the present invention, the machine 10,through described with respect to utilizing polyester fiber material M1,M2 in association with the respective rolls R1, R2, can be varied inoperation by utilizing other materials, and one particular modificationis illustrated in FIGS. 13 and 14 of the drawings wherein the roll R2 ofpolyester fiber material M2 of FIG. 1 has been eliminated andsubstituted therefor is a roll R′2 of conventional convoluted foam latexmaterial M′2 defined by a relatively flat inner/upper surface S′u and aconvoluted outer lower surface S′1, the latter being defined by aplurality of downwardly/outwardly projecting peaks P′ andoutwardly/downwardly opening valleys V′. Latex particles L′,corresponding to the latex particles L of FIG. 1, are deposited upon anupper surface U′s of a lower layer or web L′1 of polyester fibermaterial M′1 upon which is superimposed a layer or web L′2 drawn fromthe roll R′2 resulting in the valleys V′ being substantially filled withthe pieces of latex L′. Thus, as is best illustrated in FIG. 14, each ofthe valleys V′ defines a substantially closed pocket C′p substantiallyentirely filled by the latex L′ thereby assuring the absence ofmigration thereof, just as in the case of the pockets Cp of FIG. 15, butabsent the quilting thereof. However, the eventually formed laminate L′mcan be stitched utilizing the conventional quilting machine Qm of FIG.15, but the quilting need not be specifically utilized to achievenonmigration of the latex L′.

[0064] Although a preferred embodiment of the invention has beenspecifically illustrated and described herein, it is to be understoodthat minor variations may be made in the apparatus without departingfrom the spirit and scope of the invention, as defined the appendedclaims.

What is claimed is:
 1. A machine for manufacturing a laminateparticularly adapted for bedding, padding, upholstering and likeapplications comprising first means for feeding an indeterminate lengthof a first material along a predetermined first path of travel from asource of the first material to a downstream assembly area, second meansfor feeding an indeterminate length of second material along apredetermined second path of travel from a source of the second materialto the downstream assembly area, means for depositing a multiplicity ofsubstantially yieldable cushioning materials upon an upper surface ofone of the first and second indeterminate lengths of material during thefeeding thereof between the respective sources and the assembly area,means for sandwiching the cushioning material between the indeterminatelengths of first and second materials to form a laminate therefrom, andmeans for rolling the laminate into a roll.
 2. The laminatemanufacturing machine as defined in claim 1 including means for storingpackaging material adjacent the assembly area whereby the laminate rollcan be packaged in the packaging material.
 3. The laminate manufacturingmachine as defined in claim 1 including means for severing the laminatesubstantially transverse to the direction of feed of the laminate. 4.The laminate manufacturing machine as defined in claim 1 including meansfor edge-binding longitudinal edges of the laminate.
 5. The laminatemanufacturing machine as defined in claim 1 including means foredge-binding longitudinal edges of the laminate prior to being rolledinto a roll.
 6. The laminate manufacturing machine as defined in claim 1including means for edge-bonding longitudinal edges of the laminate. 7.The laminate manufacturing machine as defined in claim 1 including meansfor edge-binding longitudinal edges of the laminate, and saidedge-binding means includes means for applying an adhesive to alongitudinal edge of at least one of the first and second indeterminatelengths of material.
 8. The laminate manufacturing machine as defined inclaim 1 including means for edge-binding longitudinal edges of thelaminate, and said edge-binding means includes means for spraying anadhesive to a longitudinal edge of at least one of the first and secondindeterminate lengths of material.
 9. The laminate manufacturing machineas defined in claim 1 including means for compressing the laminate. 10.The laminate manufacturing machine as defined in claim 1 including meansfor forming cushioning materials anti-migration areas between the firstand second materials.
 11. The laminate manufacturing machine as definedin claim 1 including stitching means for forming cushioning materialsanti-migration areas between the first and second materials.
 12. Thelaminate manufacturing machine as defined in claim 1 including means foredge-binding longitudinal edges of the laminate, and means forcompressing the laminate longitudinal edges.
 13. The laminatemanufacturing machine as defined in claim 1 including first rollsupporting means for supporting a roll of the first material, secondroll supporting means for supporting a roll of the second material, thefirst and second roll supporting means being located respectivelyupstream and downstream of said depositing means, and the first materialis fed beneath said depositing means whereby the cushioning materialsare deposited upon an upper surface of the first material.
 14. Thelaminate manufacturing machine as defined in claim 1 wherein thedepositing means includes trough means for housing a supply of thecushioning material.
 15. The laminate manufacturing machine as definedin claim 1 wherein the depositing means includes trough means forhousing a supply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, and opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material.
 16. The laminate manufacturing machine asdefined in claim 1 wherein the depositing means includes trough meansfor housing a supply of the cushioning material, said trough means beingin substantially transverse spanning relationship to the feedingdirection of the first material, opening means along said trough meansthrough which pass the cushioning materials incident to the depositingthereof upon the first material, and means for regulating the passage ofthe cushioning materials through the opening means.
 17. The laminatemanufacturing machine as defined in claim 1 wherein the depositing meansincludes trough means for housing a supply of the cushioning material,said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,and means for facilitating the removal of the opening means and thereplacement thereof by different opening means to thereby selectivelyvary the deposition of the cushioning materials upon the first material.18. The laminate manufacturing machine as defined in claim 1 wherein thedepositing means includes trough means for housing a supply of thecushioning material, said trough means being in substantially transversespanning relationship to the feeding direction of the first material,opening means along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,and rotatable feed means for regulating the passage of the cushioningmaterials through the opening means.
 19. The laminate manufacturingmachine as defined in claim 1 wherein the depositing means includestrough means for housing a supply of the cushioning material, saidtrough means being in substantially transverse spanning relationship tothe feeding direction of the first material, opening means along saidtrough means through which pass the cushioning materials incident to thedepositing thereof upon the first material, and means for selectivelyvarying the size of said opening means.
 20. The laminate manufacturingmachine as defined in claim 1 wherein the depositing means includestrough means for housing a supply of the cushioning material, saidtrough means being in substantially transverse spanning relationship tothe feeding direction of the first material, opening means along saidtrough means through which pass the cushioning materials incident to thedepositing thereof upon the first material, said opening means being aslot extending substantially along the length of said trough means, andmeans for selectively adjusting the transverse dimension of said slot tothereby regulate the deposition of the cushioning materials upon thefirst material.
 21. The laminate manufacturing machine as defined inclaim 1 wherein the depositing means includes trough means for housing asupply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material, said opening means being a slot extendingsubstantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial, said slot being defined in part by a movable trough platehaving a lower edge in part defining said slot, and said adjusting meansincludes means for moving said trough plate and its lower edge tothereby adjust the transverse dimension of said slot.
 22. The laminatemanufacturing machine as defined in claim 1 wherein the depositing meansincludes trough means for housing a supply of the cushioning material,said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,said opening means being a slot extending substantially along the lengthof said trough means, means for selectively adjusting the transversedimension of said slot to thereby regulate the deposition of thecushioning materials upon the first material, said slot being defined inpart by a pivotable trough plate having a lower edge in part definingsaid slot, and said adjusting means includes means for pivoting saidtrough plate and its lower edge to thereby adjust the transversedimension of said slot.
 23. The laminate manufacturing machine asdefined in claim 1 wherein the depositing means includes trough meansfor housing a supply of the cushioning material, said trough means beingin substantially transverse spanning relationship to the feedingdirection of the first material, opening means along said trough meansthrough which pass the cushioning materials incident to the depositingthereof upon the first material, said opening means being a slotextending substantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial, and rotatable feed means for regulating the passage of thecushioning materials through the slot.
 24. The laminate manufacturingmachine as defined in claim 1 wherein the depositing means includestrough means for housing a supply of the cushioning material, saidtrough means being in substantially transverse spanning relationship tothe feeding direction of the first material, opening means along saidtrough means through which pass the cushioning materials incident to thedepositing thereof upon the first material, said opening means being aslot extending substantially along the length of said trough means,means for selectively adjusting the transverse dimension of said slot tothereby regulate the deposition of the cushioning materials upon thefirst material, said slot being defined in part by a pivotable troughplate having a lower edge in part defining said slot, said adjustingmeans includes means for pivoting said trough plate and its lower edgeto thereby adjust the transverse dimension of said slot, and rotatablefeed means for regulating the passage of the cushioning materialsthrough the slot.
 25. The laminate manufacturing machine as defined inclaim 1 including first roll supporting means for supporting a roll ofthe first material, second roll supporting means for supporting a rollof the second material, the first and second roll supporting means beinglocated respectively upstream and downstream of said depositing means,the first material is fed beneath said depositing means whereby thecushioning materials are deposited upon an upper surface of the firstmaterial, and means for drivingly rotating said rolling means to therebyautomatically draw the first and second materials toward the assemblyarea.
 26. The laminate manufacturing machine as defined in claim 1including first roll supporting means for supporting a roll of the firstmaterial, second roll supporting means for supporting a roll of thesecond material, the first and second roll supporting means beinglocated respectively upstream and downstream of said depositing means,the first material is fed beneath said depositing means whereby thecushioning materials are deposited upon an upper surface of the firstmaterial, means for drivingly rotating said rolling means to therebyautomatically draw the first and second materials toward the assemblyarea, and means for restraining free-wheeling unrolling of the firstmaterial.
 27. The laminate manufacturing machine as defined in claim 1including first roll supporting means for supporting a roll of the firstmaterial, second roll supporting means for supporting a roll of thesecond material, the first and second roll supporting means beinglocated respectively upstream and downstream of said depositing means,the first material is fed beneath said depositing means whereby thecushioning materials are deposited upon an upper surface of the firstmaterial, means for drivingly rotating said rolling means to therebyautomatically draw the first and second materials toward the assemblyarea, and means for adjustably braking the unrolling of the firstmaterial.
 28. The laminate manufacturing machine as defined in claim 1including first roll supporting means for supporting a roll of the firstmaterial, second roll supporting means for supporting a roll of thesecond material, the first and second roll supporting means beinglocated respectively upstream and downstream of said depositing means,the first material is fed beneath said depositing means whereby thecushioning materials are deposited upon an upper surface of the firstmaterial, means for drivingly rotating said rolling means to therebyautomatically draw the first and second materials toward the assemblyarea, and means for placing the first material under tension upstream ofthe depositing means.
 29. The laminate manufacturing machine as definedin claim 1 wherein the depositing means includes a trough disposed insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along a bottom of said troughthrough which pass the cushioning materials incident to the depositingthereof upon the first material, a chute substantially surrounding saidopening means and extending downwardly toward the first material, and alower terminal edge of said chute being spaced slightly above the firstmaterial.
 30. The laminate manufacturing machine as defined in claim 1wherein the depositing means includes a trough disposed in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along a bottom of said trough through which passthe cushioning materials incident to the depositing thereof upon thefirst material, a chute substantially surrounding said opening means andextending downwardly toward the first material, a lower terminal edge ofsaid chute being spaced slightly above the first material, and means formaintaining a space between said chute terminal edge and the firstmaterial.
 31. The laminate manufacturing machine as defined in claim 1including first roll supporting means for supporting a roll of the firstmaterial, means for driving said rotating means to thereby automaticallydraw the first and second materials through the assembly area and into alaminate roll, and means for selectively varying the speed of saiddriving means.
 32. The laminate manufacturing machine as defined inclaim 1 including first roll supporting means for supporting a roll ofthe first material, means for driving said rotating means to therebyautomatically draw the first and second materials through the assemblyarea and into a laminate roll, means for selectively varying the speedof said driving means, and means for applying selective varying brakingto said first roll supporting means.
 33. The laminate manufacturingmachine as defined in claim 1 including first roll supporting means forsupporting a roll of the first material, means for driving said rotatingmeans to thereby automatically draw the first and second materialsthrough the assembly area and into a laminate roll, means forselectively varying the speed of said driving means, means for applyingselective varying braking to said first roll supporting means, and meansfor placing the first material under tension between said first rollsupporting means and said depositing means.
 34. The laminatemanufacturing machine as defined in claim 2 including means foredge-binding longitudinal edges of the laminate.
 35. The laminatemanufacturing machine as defined in claim 2 including first rollsupporting means for supporting a roll of the first material, secondroll supporting means for supporting a roll of the second material, thefirst and second roll supporting means being located respectivelyupstream and downstream of said depositing means, and the first materialis fed beneath said depositing means whereby the cushioning materialsare deposited upon an upper surface of the first material.
 36. Thelaminate manufacturing machine as defined in claim 2 wherein thedepositing means includes trough means for housing a supply of thecushioning material, said trough means being in substantially transversespanning relationship to the feeding direction of the first material,opening means along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,and means for regulating the passage of the cushioning materials throughthe opening means.
 37. The laminate manufacturing machine as defined inclaim 2 wherein the depositing means includes trough means for housing asupply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material, and means for facilitating the removal of theopening means and the replacement thereof by different opening means tothereby selectively vary the deposition of the cushioning materials uponthe first material.
 38. The laminate manufacturing machine as defined inclaim 2 wherein the depositing means includes trough means for housing asupply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material, said opening means being a slot extendingsubstantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial, said slot being defined in part by a movable trough platehaving a lower edge in part defining said slot, and said adjusting meansincludes means for moving said trough plate and its lower edge tothereby adjust the transverse dimension of said slot.
 39. The laminatemanufacturing machine as defined in claim 2 wherein the depositing meansincludes trough means for housing a supply of the cushioning material,said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,said opening means being a slot extending substantially along the lengthof said trough means, means for selectively adjusting the transversedimension of said slot to thereby regulate the deposition of thecushioning materials upon the first material, said slot being defined inpart by a pivotable trough plate having a lower edge in part definingsaid slot, and said adjusting means includes means for pivoting saidtrough plate and its lower edge to thereby adjust the transversedimension of said slot.
 40. The laminate manufacturing machine asdefined in claim 2 wherein the depositing means includes trough meansfor housing a supply of the cushioning material, said trough means beingin substantially transverse spanning relationship to the feedingdirection of the first material, opening means along said trough meansthrough which pass the cushioning materials incident to the depositingthereof upon the first material, said opening means being a slotextending substantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial, and rotatable feed means for regulating the passage of thecushioning materials through the slot.
 41. The laminate manufacturingmachine as defined in claim 2 wherein the depositing means includes atrough disposed in substantially transverse spanning relationship to thefeeding direction of the first material, opening means along a bottom ofsaid trough through which pass the cushioning materials incident to thedepositing thereof upon the first material, a chute substantiallysurrounding said opening means and extending downwardly toward the firstmaterial, and a lower terminal edge of said chute being spaced slightlyabout the first material.
 42. The laminate manufacturing machine asdefined in claim 2 including first roll supporting means for supportinga roll of the first material, means for driving said rotating means tothereby automatically draw the first and second materials through theassembly area and into a laminate roll, and means for selectivelyvarying the speed of said driving means.
 43. The laminate manufacturingmachine as defined in claim 2 including first roll supporting means forsupporting a roll of the first material, means for driving said rotatingmeans to thereby automatically draw the first and second materialsthrough the assembly area and into a laminate roll, means forselectively varying the speed of said driving means, and means forapplying selective varying braking to said first roll supporting means.44. The laminate manufacturing machine as defined in claim 4 includingfirst roll supporting means for supporting a roll of the first material,second roll supporting means for supporting a roll of the secondmaterial, the first and second roll supporting means being locatedrespectively upstream and downstream of said depositing means, and thefirst material is fed beneath said depositing means whereby thecushioning materials are deposited upon an upper surface of the firstmaterial.
 45. The laminate manufacturing machine as defined in claim 4wherein the depositing means includes trough means for housing a supplyof the cushioning material, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thecushioning materials incident to the depositing thereof upon the firstmaterial, and means for regulating the passage of the cushioningmaterials through the opening means.
 46. The laminate manufacturingmachine as defined in claim 4 wherein the depositing means includestrough means for housing a supply of the cushioning material, saidtrough means being in substantially transverse spanning relationship tothe feeding direction of the first material, opening means along saidtrough means through which pass the cushioning materials incident to thedepositing thereof upon the first material, and means for facilitatingthe removal of the opening means and the replacement thereof bydifferent opening means to thereby selectively vary the deposition ofthe cushioning materials upon the first material.
 47. The laminatemanufacturing machine as defined in claim 4 wherein the depositing meansincludes trough means for housing a supply of the cushioning material,said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,said opening means being a slot extending substantially along the lengthof said trough means, means for selectively adjusting the transversedimension of said slot to thereby regulate the deposition of thecushioning materials upon the first material, said slot being defined inpart by a movable trough plate having a lower edge in part defining saidslot, and said adjusting means includes means for moving said troughplate and its lower edge to thereby adjust the transverse dimension ofsaid slot.
 48. The laminate manufacturing machine as defined in claim 4wherein the depositing means includes trough means for housing a supplyof the cushioning material, said trough means being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along said trough means through which pass thecushioning materials incident to the depositing thereof upon the firstmaterial, said opening means being a slot extending substantially alongthe length of said trough means, means for selectively adjusting thetransverse dimension of said slot to thereby regulate the deposition ofthe cushioning materials upon the first material, said slot beingdefined in part by a pivotable trough plate having a lower edge in partdefining said slot, and said adjusting means includes means for pivotingsaid trough plate and its lower edge to thereby adjust the transversedimension of said slot.
 49. The laminate manufacturing machine asdefined in claim 4 wherein the depositing means includes trough meansfor housing a supply of the cushioning material, said trough means beingin substantially transverse spanning relationship to the feedingdirection of the first material, opening means along said trough meansthrough which pass the cushioning materials incident to the depositingthereof upon the first material, said opening means being a slotextending substantially along the length of said trough means, means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial, and rotatable feed means for regulating the passage of thecushioning materials through the slot.
 50. The laminate manufacturingmachine as defined in claim 4 wherein the depositing means includes atrough disposed in substantially transverse spanning relationship to thefeeding direction of the first material, opening means along a bottom ofsaid trough through which pass the cushioning materials incident to thedepositing thereof upon the first material, a chute substantiallysurrounding said opening means and extending downwardly toward the firstmaterial, and a lower terminal edge of said chute being spaced slightlyabout the first material.
 51. The laminate manufacturing machine asdefined in claim 10 including means for edge-binding longitudinal edgesof the laminate.
 52. The laminate manufacturing machine as defined inclaim 10 wherein the depositing means includes trough means for housinga supply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material, and means for regulating the passage of thecushioning materials through the opening means.
 53. The laminatemanufacturing machine as defined in claim 10 wherein the depositingmeans includes trough means for housing a supply of the cushioningmaterial, said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,said opening means being a slot extending substantially along the lengthof said trough means, and means for selectively adjusting the transversedimension of said slot to thereby regulate the deposition of thecushioning materials upon the first material.
 54. The laminatemanufacturing machine as defined in claim 11 including means foredge-binding longitudinal edges of the laminate.
 55. The laminatemanufacturing machine as defined in claim 11 wherein the depositingmeans includes trough means for housing a supply of the cushioningmaterial, said trough means being in substantially transverse spanningrelationship to the feeding direction of the first material, openingmeans along said trough means through which pass the cushioningmaterials incident to the depositing thereof upon the first material,and means for regulating the passage of the cushioning materials throughthe opening means.
 56. The laminate manufacturing machine as defined inclaim 11 wherein the depositing means includes trough means for housinga supply of the cushioning material, said trough means being insubstantially transverse spanning relationship to the feeding directionof the first material, opening means along said trough means throughwhich pass the cushioning materials incident to the depositing thereofupon the first material, said opening means being a slot extendingsubstantially along the length of said trough means, and means forselectively adjusting the transverse dimension of said slot to therebyregulate the deposition of the cushioning materials upon the firstmaterial.
 57. The laminate manufacturing machine as defined in claim 11wherein the depositing means includes a trough disposed in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, opening means along a bottom of said trough through which passthe cushioning materials incident to the depositing thereof upon thefirst material, a chute substantially surrounding said opening means andextending downwardly toward the first material, a lower terminal edge ofsaid chute being spaced slightly above the first material, and means formaintaining a space between said chute terminal edge and the firstmaterial.
 58. A method of manufacturing a laminate particularly adaptedfor bedding, padding upholstering and like applications comprising thesteps of feeding an indeterminate length of a first material along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial along a predetermined second path of travel from a source ofthe second material to the downstream assembly area, depositing amultiplicity of substantially yieldable cushioning materials upon anupper surface of one of the first and second indeterminate lengths ofmaterial during the feeding thereof between the respective sources andthe assembly area, sandwiching the cushioning materials between theindeterminate lengths of first and second materials to form a laminatetherefrom, and rolling the laminate into a roll.
 59. The laminatingmethod as defined in claim 58 including the step of storing packagingmaterial adjacent the assembly area whereby the laminate roll can bepackaged in the packaging material.
 60. The laminating method as definedin claim 58 including the step of severing the laminate substantiallytransverse to the direction of feed of the laminate.
 61. The laminatemethod as defined in claim 58 including the step of edge-bindinglongitudinal edges of the laminate.
 62. The laminate method as definedin claim 58 including the step of edge-binding longitudinal edges of thelaminate prior to being rolled into a roll.
 63. The laminate method asdefined in claim 58 including the step of edge-bonding longitudinaledges of the laminate.
 64. The laminate method as defined in claim 58including the step of edge-binding longitudinal edges of the laminate,and performing the edge-binding step by applying an adhesive to alongitudinal edge of at least one of the first and second indeterminatelengths of material.
 65. The laminate method as defined in claim 58including the step of edge-binding longitudinal edges of the laminate,and said edge-binding step by spraying an adhesive to a longitudinaledge of at least one of the first and second indeterminate lengths ofmaterial.
 66. The laminate method as defined in claim 58 including thestep of forming areas between the first and second materials withinwhich the cushioning materials are confined.
 67. The laminate method asdefined in claim 58 including the step of stitching pockets between thefirst and second materials within which the cushioning materials areconfined.
 68. The laminate method as defined in claim 58 including thestep of stitching substantially closed pockets between the first andsecond materials within which the cushioning materials are confined. 69.The laminate method as defined in claim 58 including the step ofcreating a plurality of downwardly opening valleys in a lower surface ofthe other of the first and second indeterminate lengths of materialwhich substantially house the cushioning materials therein incident toperforming the sandwiching step.
 70. The laminate method as defined inclaim 58 including the steps of supporting a roll of the first material,supporting a roll of the second material, the first and second rollsupporting steps being performed at locations respectively upstream anddownstream of a point at which the depositing step is performed, andfeeding the first material beneath the depositing point whereby thecushioning materials are deposited upon an upper surface of the firstmaterial.
 71. The laminate method as defined in claim 58 wherein thedepositing step is effected from a trough housing a supply of thecushioning material.
 72. The laminate method as defined in claim 58wherein the depositing step is effected from a trough housing a supplyof the cushioning material, the trough being in substantially transversespanning relationship to the feeding direction of the first material,and the trough includes openings through which pass the cushioningmaterials incident to the performance of the depositing step.
 73. Thelaminate method as defined in claim 58 wherein the depositing step iseffected from a trough housing a supply of the cushioning material, thetrough being in substantially transverse spanning relationship to thefeeding direction of the first material, the trough includes openingsthrough which pass the cushioning materials incident to the depositingstep, and regulating the passage of the cushioning materials through thetrough openings.
 74. The laminate method as defined in claim 58 whereinthe depositing step is effected from a trough housing a supply of thecushioning material, the trough being in substantially transversespanning relationship to the feeding direction of the first material,the trough includes openings through which pass the cushioning materialsincident to the performance of the depositing step, and removing thetrough openings and replacing the trough openings with different troughopenings to thereby selectively vary the deposition of the cushioningmaterials upon the first material.
 75. The laminate method as defined inclaim 58 wherein the depositing step is effected from a trough housing asupply of the cushioning material, the trough being in substantiallytransverse spanning relationship to the feeding direction of the firstmaterial, the trough includes opening through which pass the cushioningmaterials incident to the performance of the depositing step, andselectively varying the size of the trough opening.
 76. The laminatemethod as defined in claim 58 wherein the depositing step is effectedfrom a trough housing a supply of the cushioning material, the troughbeing in substantially transverse spanning relationship to the feedingdirection of the first material, the trough includes opening throughwhich pass the cushioning materials incident to the performance of thedepositing step, selectively varying the size of the trough opening, thetrough opening being a slot extending substantially along the length ofsaid trough, and selectively adjusting the transverse dimension of theslot to thereby regulate the deposition of the cushioning materials uponthe first material.
 77. A method of manufacturing a laminateparticularly adapted for bedding, padding, upholstering and likeapplications comprising the steps of feeding an indeterminate length ofa first material along a predetermined first path of travel from asource of the first material to a downstream assembly area, feeding anindeterminate length of second material along a predetermined secondpath of travel from a source of the second material to the downstreamassembly area, depositing a multiplicity of substantially yieldablecushioning materials from an upper surface of one of the first andsecond indeterminate lengths of material during the feeding thereofbetween the respective sources and the assembly area, sandwiching thecushioning materials between the indeterminate lengths of first andsecond materials to form a laminate therefrom, and quilting thelaminate.
 78. The laminating method as defined in claim 77 wherein thequilting step is performed by stitching which substantially reducesmigration of the cushioning materials.
 79. The laminating method asdefined in claim 77 wherein the quilting step is performed by stitchingsubstantially closed pockets between the first and second materialswhich substantially reduces migration of the cushioning materials.
 80. Amethod of manufacturing a laminate particularly adapted for bedding,padding, upholstering and like applications comprising the steps offeeding an indeterminate length of first material having oppositesurfaces along a predetermined first path of travel from a source of thefirst material to a downstream assembly area, feeding an indeterminatelength of second material having opposite surfaces along a predeterminedsecond path of travel from a source of the second material to theassembly area, depositing a multiplicity of substantially yieldablecushioning materials upon an upper surface of one of the first andsecond indeterminate length material during the feeding thereof betweenthe respective sources and the assembly area prior to sandwiching thecushioning materials between the upper surface of the one material and alower surface of another of the first and second indeterminate lengthmaterials, at least one of the upper and lower surfaces being aconvoluted surface defined by peaks and valleys, and sandwiching thecushioning materials between the indeterminate lengths of first andsecond materials to form a laminate therefrom and during the sandwichingof the first and second materials confining the cushioning materials inthe valleys.
 81. The laminating method as defined in claim 80 whereinthe indeterminate length material having the convoluted surface islatex.
 82. The laminating method as defined in claim 80 wherein theconvoluted surface is the lower surface.
 83. The laminating method asdefined in claim 80 wherein the convoluted surface is the upper surface.84. The laminating method as defined in claim 80 wherein the convolutedsurface is the lower surface of an uppermost of the first and secondindeterminate length materials.
 85. The laminating method as defined inclaim 80 wherein the convoluted surface is the upper surface of alowermost of the first and second indeterminate length materials. 86.The laminating method as defined in claim 80 wherein the convolutedsurface is the lower surface of an uppermost of the first and secondindeterminate length materials, and the upper surface is a substantiallyplanar surface of a lowermost of the first and second indeterminatelength materials.
 87. The laminating method as defined in claim 80wherein the convoluted surface is the upper surface of a lowermost ofthe first and second indeterminate length materials, and the lowersurface is a substantially planar surface of an uppermost of the firstand second indeterminate length materials.
 88. The laminating method asdefined in claim 80 wherein the convoluted surface is the lower surfaceof an uppermost of the first and second indeterminate length materials,the upper surface is a substantially planar surface of a lowermost ofthe first and second indeterminate length materials, and crest portionsof the peaks contact the planar surface.
 89. The laminating method asdefined in claim 80 wherein the convoluted surface is the upper surfaceof a lowermost of the first and second indeterminate length materials,the lower surface is a substantially planar surface of an uppermost ofthe first and second indeterminate length materials, and crest portionsof the peaks contact the planar surface.
 90. The laminating method asdefined in claim 80 wherein the volume of cushioning materials depositedupon the upper surface is substantially confined in the valleys.
 91. Thelaminating method as defined in claim 80 including the step ofedge-binding longitudinal edges of the laminate.
 92. The laminatingmethod as defined in claim 80 including the step of edge-bondinglongitudinal edges of the laminate.
 93. The laminating method as definedin claim 80 including the step of rolling the laminate into a roll. 94.The laminating method as defined in claim 80 wherein the indeterminatelength material having the convoluted surface is latex, and thecushioning materials are latex.
 95. The laminating method as defined inclaim 84 wherein the indeterminate length material having the convolutedsurface is latex, and the cushioning materials are latex.
 96. Thelaminating method as defined in claim 87 wherein the indeterminatelength material having the convoluted surface is latex, and thecushioning materials are latex.
 97. The laminating method as defined inclaim 88 wherein the indeterminate length material having the convolutedsurface is latex, and the cushioning materials are latex.
 98. A methodof manufacturing a laminate particularly adapted for bedding, padding,upholstering and like applications comprising the steps of feeding anindeterminate length of first material having opposite surfaces along apredetermined first path of travel from a source of the first materialto a downstream assembly area, feeding an indeterminate length of secondmaterial having opposite surfaces along a predetermined second path oftravel from a source of the second material to the assembly area,depositing a multiplicity of substantially yieldable cushioningmaterials upon an upper surface of one of the first and secondindeterminate length materials during the feeding thereof between therespective sources and the assembly area prior to sandwiching thecushioning materials between the upper surface of the one material and alower surface of another of the first and second indeterminate lengthmaterials, and the volume of cushioning materials deposited upon theupper surface is substantially in the range of 0.15-0.50 pound persquare yard.
 99. The laminating method as defined in claim 98 whereinthe cushioning materials are latex.
 100. The laminating method asdefined in claim 98 wherein the cushioning materials are an admixture oflatex and down.
 101. The laminating method as defined in claim 98wherein the cushioning materials are substantially 50%-50% admixture ofdown and latex.
 102. The laminating method as defined in claim 98wherein the indeterminate length materials are each polyester fiber, andthe cushioning materials are latex.
 103. The laminating method asdefined in claim 98 wherein one of the indeterminate length materials islatex and another of the indeterminate length materials is polyesterfiber.
 104. The laminating method as defined in claim 98 wherein one ofthe indeterminate length materials is latex and another of theindeterminate length materials is polyester fiber, the one indeterminatelength material includes a convoluted surface defined by peaks andvalleys, and the cushioning materials are housed in the valleys.
 105. Amethod of manufacturing a laminate particularly adapted for bedding,padding, upholstering and like applications comprising the steps offeeding an indeterminate length of first material having oppositesurfaces along a predetermined first path of travel from a source of thefirst material to a downstream assembly area, feeding an indeterminatelength of second material having opposite surfaces along a predeterminedsecond path of travel from a source of the second material to theassembly area, depositing a multiplicity of substantially yieldablecushioning materials upon an upper surface of one of the first andsecond indeterminate length materials during the feeding thereof betweenthe respective sources and the assembly area prior to sandwiching thecushioning materials between the upper surface of the one material and alower surface of another of the first and second indeterminate lengthmaterials, and stitching a plurality of anti-migratory areas between thefirst and second indeterminate length materials within which cushioningmaterials are confined and substantially precluded from migratingtherefrom.
 106. The laminating method as defined in claim 105 whereinthe stitched anti-migratory areas are substantially pockets.
 107. Thelaminating method as defined in claim 105 wherein the stitchedanti-migratory areas are substantially closed pockets.
 108. Thelaminating method as defined in claim 105 wherein the stitchedanti-migratory areas are substantially narrow channels.
 109. Thelaminating method as defined in claim 105 wherein the stitchedanti-migratory areas are substantially narrow crossing channels. 110.The laminating method as defined in claim 105 wherein the stitchedanti-migratory areas are substantially narrow sinusoidal channels.